Download Installation Instructions

Parts
Installation
Instructions
A
B
C
D
DESCRIPTION
Alignment Tab
Drill Guide
Actuator Cable Assembly
72” Actuator Cable
C1
5/16” Jam Nut
C2
Star Washer
C3
1/4” Hex Nut
C4
Actuator Cable Stud
C5
Wire Nut Connector
PART #
PN ESB101
PN ESB102
PN ESB103
PN 721245
QTY
1
1
1
1
1
1
2
1
3
Product: Electronic Swaybar Cable Conversion
Part Number: PN 9500
Tools Required
Application: Jeep® Wrangler JK, 2007+
Welcome
Congratulations on purchasing a new Electronic
®
Swaybar Cable Conversion from JKS Manufacturing.
We are committed to providing you with the best
products available and your satisfaction is our first
priority.
We hope you enjoy your JKS® purchase and are here
to help if you still have questions after reviewing this
safety information and instructions. Contact us online at
www.jksmfg.com or by phone at 308-762-6949.
JKS Electronic Swaybar Cable Conversion Installation
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Metric/Standard Socket Wrench Set
Torque Wrench
1/2", 7/8” & 15/16” Open End Wrenches
Electric Drill with the following bits
• 1/8”
• 3/16”
• 5/8”
• Size I (0.272”)
• 9/32”
5/16” -24 Thread Tap
C Clamp (2” with 2” throat or larger)
1/8” Steel Punch
Wire Cutters
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Flat Head Screwdriver
WD-40 (or similar lubricant for cutting threads in aluminum)
Blue Painter’s Masking Tape (or equivalent)
Medium Strength Thread Locking Compound
Factory Service Manual (recommended to remove and reinstall sway bar
assembly on vehicle)
Always Wear Protective Gear
Safety glasses and protective gloves are required.
PN 9500
Page 1 of 9
Important Product
Safety Information
Higher Rollover Risk
For your safety and the safety of others, please read all
instructions and warnings in this pamphlet and your
Jeep® owner’s manual and off road driving supplement
before attempting installation. Within these instructions
the following signal words refer to important product
safety information:
Indicates hazards or unsafe situations which could
result in severe personal injury or death.
Indicates hazards or unsafe situations which could
result in property damage or minor to moderate
personal injury.
Modifying your Jeep® to improve off-road performance
may result in vehicle handling different than as factory
equipped, including increased ride-height and/or
chassis articulation; reduced lateral stability and higher
risk of roll-over or other accident. Also, owner’s choice
of larger tire and wheel combinations may require
additional braking force or increased stopping
distances.
To reduce risk of serious injury and accident:
Careful attention is required to this operation that
generally does not relate to personal injury, although
damage to your JKS product or other property may
result if you fail to follow instructions.
JKS Electronic Swaybar Cable Conversion Installation

Choose modifications that balance your actual
highway & off-road use.
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Avoid sharp turns, abrupt maneuvers or steep
side-cambers.
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Avoid other maneuvering conditions which
may cause the vehicle to trip, roll, lose traction
or compromise your ability to safely brake in
an emergency.
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Routinely inspect your vehicle components for
unusual wear or off-road damage. Repair or
Replace any unserviceable components
before use.
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Do not modify or combine body lifts with other
mechanical lifts contrary to manufacturers’ or
Jeep® recommendations & warnings.
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Acquaint any other drivers with your vehicle
modifications and handling.
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Always wear seat belts and/or appropriate offroad restraints, reduce your speed, Tread
Lightly©.
PN 9500
Page 2 of 9
 Locate the seven rivets that secure the plastic
Professional Installation Only
plunger housing from the electric motor
housing.
 Pull the electric motor and gearbox from the
motor housing so that you can access the
wires.
This product should only be installed by a professional
mechanic or individual with considerable technical
experience and the proper tools.
Stay Connected On-road
On-highway safety is enhanced by controlling body roll.
Never disconnect swaybar when operating on public
roads.
Installation
 1. DISSASSEMBLY
 Remove electronic swaybar assembly from
 Using a wire cutter, cut the wires close to the
 Using a 1/8” drill bit, drill out all seven rivets.
Don’t drill all the way through. Just
break through the lip and tap the remaining
part of the rivet out using a 1/8” steel punch.
electric motor and gearbox so that the
remaining wires from the motor housing are
long enough to work with. Discard electric
motor and gearbox as they will not be used
during reassembly.
vehicle per the factory service manual
instructions for your vehicle.
 Using the 3 supplied Wire Nut Connectors (D),
 Remove the three M10 bolts that secure the
electric motor housing to the main gear
housing. Separate the motor housing from the
gear housing as pictured below.
 Separate the plastic plunger housing from the
motor housing.
cap off the red and white wires separately.
Then combine the 2 black wires and cap them
off using the remaining wire nut. Hint: Do not
strip insulation from ends of wires.
RED
WHITE
BLACK
 Remove and discard all of the parts between
BLACK
the plunger housing and electric motor
housing. These parts will not be reused.
JKS Electronic Swaybar Cable Conversion Installation
PN 9500
Page 3 of 9
 Place the plastic plunger housing on a
workbench to prevent any damage to the
housing during the next step.
 Discard clock spring as it will no longer be
used.
 Using a 9/32” drill bit, drill out the plastic
threads from the plunger mechanism.
 Separate plunger mechanism from plunger
housing.
 Locate and remove the brass bushing and flat
washer from the plastic plunger housing.
 Unscrew worm shaft from plunger mechanism
and discard as it will no longer be used.
 Using a 1/8” punch, carefully drive the worm
shaft through the worm shaft coupler.
Spring Under Tension
This will free the clock spring underneath the
worm shaft coupler causing it to rapidly
unwind. Use caution to prevent injury to
yourself from unwinding spring.
JKS Electronic Swaybar Cable Conversion Installation
 Locate the internal threads inside the plunger
 Remove the five M10 bolts that secure the two
halves of the main gear housing together.
mechanism into which the worm shaft was
threaded.
PN 9500
Page 4 of 9
 Separate the main gear housing and retain the
gasket seal for reassembly.
 Remove the grease from the stepped portion
of the housing as pictured to prepare for
drilling.
 Insert the Drill Guide (B) into spring pocket in
housing as pictured. Use a clamp to hold the
Drill Guide in position during drilling.
Save the grease as it will be
reapplied during final assembly.
 Remove the coil spring, engagement fork and
splined collar from the main gear housing.
Retain these parts for reassembly.
 Using a 3/16” drill bit, insert the drill into the
 Protect the rest of the housing from debris by
covering with blue masking tape or equivalent.
guide and drill a pilot hole through the
housing.
 Remove the Drill Guide and enlarge the hole
 Locate the supplied steel Drill Guide (B).
JKS Electronic Swaybar Cable Conversion Installation
PN 9500
using a size I (0.272”) drill bit.
Page 5 of 9
 Using a 5/16” -24 thread tap, cut threads in
the enlarged hole.
Use WD-40 or appropriate
lubricant during the tapping process and hold
the tap in line with the hole. Every few turns,
back the tap out to clear away any metal
chips. Clean up all of the metal chips.
 Using a 3/16” drill bit, insert the drill into the
guide and drill a pilot hole through the
engagement fork.
 2. PREPARE CABLE FOR
INSTALLATION
Before installing Actuator Cable
(C), the 5/16” Jam Nut (C2) and Star Washer
(C3) on the threaded end must be reversed.
To prevent the star washer from getting lost
during shipping, it was placed on the actuator
cable before the jam nut.
 First remove the two 1/4” Hex Nuts (C4) from
the Actuator Cable Stud (C5). Set both nuts
aside for the moment. Next remove the larger
5/16” Jam Nut (C2) and Star Washer (C3)
from the cable. Then fully thread the jam nut
back onto the cable, followed by the star
washer.
 With the housing drilled and tapped, you are
now going to drill a hole in the engagement
fork so the cable can pass through it. Use the
same Drill Guide (B) as used previously.
 Insert the base of the Drill Guide (B) into the
 Remove the Drill Guide and enlarge the hole
using a 9/32” drill bit.
JKS Electronic Swaybar Cable Conversion Installation
PN 9500
AFTER
 Clean up all of the metal chips.
BEFORE
plunger pocket on the engagement fork as
pictured. Use a clamp to hold the Drill Guide in
position during drilling.
Page 6 of 9
 3. REASSEMBLY
 Insert threaded end of Actuator Cable (C) into
 Insert the supplied small rectangular
Alignment Tab (A) into plunger mechanism
directly over the drilled hole.
threaded hole in housing. Thread the cable by
hand until the 1/2” Jam Nut (C2) restricts it
from being threaded any further.
 Using a 7/16” wrench, tighten the 1/4” Hex Nut
(C4) just enough (approximately 1/32”) to
slightly compress the coil spring inside the
plunger mechanism.
 Thread the remaining 1/4” Nut onto the stud
until it bears against the first nut, and then
tighten with wrench to lock the nuts together.
 Using a 1/2” open end wrench, tighten Jam
Nut (C2) against Star Washer (C3) until snug
to secure the Actuator Cable to the housing.
 Slide the plunger mechanism onto the
Actuator Cable Stud (C5) and press fully into
the plunger pocket in engagement fork.
 Reapply original grease to coil spring, splined
collar and engagement fork and then
reassemble as pictured below. Hint: Make
sure splines on collar are well lubricated.
 Pull the threaded end of the cable to remove
 Reinstall the lubricated assembly in the main
gear housing. Make sure the Actuator Cable
Stud (C5) passes through the hole you drilled
in the engagement fork, and that the assembly
is pushed fully into the housing.
JKS Electronic Swaybar Cable Conversion Installation
any slack and thread one of the 1/4” Hex Nuts
(C4) that was originally installed on the
actuator cable back onto the stud. Tighten nut
by hand.
PN 9500
 Before continuing reassembly, bench test the
Cable Conversion by pulling the handle on the
Actuator Cable (C) to make sure the
engagement fork pulls the splined collar
completely onto the splined gear as pictured
below.
 Place the original gasket seal on the mounting
flange of one of the main gear housing halves.
Make sure mating flange on both
halves of the housing are completely clean
and free of any debris.
Page 7 of 9
 Clock the splined collar with the splined gear
on the opposite housing half and mate the two
halves of the housing back together, while
making sure the gasket remains in place and
properly aligned.
 Mate the motor housing to the main gear
housing.
 Using a 5/8” drill bit, drill a hole through the
inner fender where the T-handle will be
mounted.
 Using a flat head screwdriver, remove the
small machine screw from the center of the Thandle.
 Secure the housings together by reinstalling
the original three M10 bolts.
 Secure the two gear housing halves together
by reinstalling the original five M10 bolts.
 Using a torque wrench, tighten all M10 bolts to
40 ft-lbs.
 Before continuing reassembly, bench test the
Cable Conversion once more by pulling the
handle on the Actuator Cable (C) and twisting
each end of the swaybar to check for
engagement and disengagement.
 Reposition plastic plunger housing onto motor
housing. No hardware will be used to secure
the plunger housing, as flange will be
sandwiched between motor housing and main
gear housing.
JKS Electronic Swaybar Cable Conversion Installation
 Using a torque wrench, tighten all M10 bolts to
40 ft-lbs.
 Reinstall electronic swaybar assembly on
vehicle per factory service manual
instructions.
 4. MOUNT T-HANDLE
 Choose a location to mount the T-handle end
 Next remove the large collar nut from the
Actuator Cable (C) using a 7/8” wrench.
 Remove the star locking washer from the
cable but leave the remaining jam nut in place.
of the Actuator Cable (C).
We suggest mounting the Thandle on the inner fender as pictured below.
This location is easily accessible and clear of
obstructions.
PN 9500
Page 8 of 9
 Insert the threaded end of the Actuator Cable
(C) through the mounting hole from inside the
engine compartment.
If you encounter any problems with your
installation and setup, please contact JKS
Manufacturing for technical assistance.
JKS Technical Support
Avoid Cable Interference
It is the installer’s responsibility to route the Actuator
Cable (C) from the swaybar assembly to the T-handle
along a path that will not interfere with any of the
vehicle’s moving parts. Avoid contact with radiator
hoses, electrical wires or brake lines. Secure the cable
to the vehicle using wire ties or equivalent.
 With the cable properly routed, reinstall the
Phone
(308) 762-6949
E-mail
[email protected]
 2012 JKS Manufacturing, Inc & Aftermarketing, LLC
Revision Date 11/7/2012
star locking washer and thread the large collar
nut onto the protruding threads of the Actuator
Cable (C) and finger tighten.
 Using a 7/8” wrench, tighten the collar nut until
it bottoms out on the Actuator Cable (C).
It may be necessary to loosen the
jam nut to allow full engagement of collar nut.
 With the collar nut installed, tighten the jam
nut against the star washer using a 15/16”
open end wrench until the Actuator Cable (C)
is securely mounted to the inner fender.
 Apply a drop of thread locking compound to
the small machine screw and reinstall the Thandle onto the cable.
 Fully cycle the suspension and steering to
make sure the Actuator Cable (C) is safely
secured.
JKS Electronic Swaybar Cable Conversion Installation
PN 9500
Page 9 of 9